Assembling Cylinder Head

Information 

Reusable inner parts of the cylinder head must always be cleaned thoroughly and assigned to their original installation location.

Information 

• The flexible rotating head of the assembly cartridge must be positioned almost on the assembly cartridge. 
• If this is not the case, the valve key mounting will not be positioned over the valve stem and the valve keys will not be moved to the correct position. 

1. Install bottom valve-spring plate -1-  .

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   Bottom valve-spring plate

2. Install new valve-stem seal -1-  .
   1. 2.1  Oil the valve stem -2-  lightly and fit assembly sleeve (shim set for valve-stem seals) -3-  .
   2. 2.2  Slide valve-stem seal over the assembly sleeve -3-  by hand.

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   Valve-stem seal

3. Press valve-stem seal with the > 9606/1 - assembly driver-1-  as far as it will go onto the valve stem.

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   Assembly driver

4. Remove > 9606/1 - assembly driver  and assembly sleeve.
5. Pick up valve keys using assembly cartridge VAS 5161/8A. 
   1. 5.1  Insert valve keys into the insertion device VAS 5161/18 -1-  .
      1. 5.1.1  Press spring washer of the insertion device VAS 5161/18 -1-  downwards and insert the valve keys with the narrow end pointing downwards.
   2. 5.2  Press assembly cartridge VAS 5161/8A -1-  onto the valve keys from above and pick up the valve keys.

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   Insertion device

6. Install valve springs and valve-spring plates.
   1. 6.1  Assign and install valve springs and valve-spring plates according to the markings made during removal.
7. Fit valve keys using assembly cartridge VAS 5161/8A -2-  .
   1. 7.1  Position assembly cartridge VAS 5161/8A -2-  on the valve stem.
   2. 7.2  Engage pressure fork VAS 5161/2 -3-  on the retainer VAS 5161/6 -1-  .
   3. 7.3  Press assembly cartridge VAS 5161/8A -2-  down using pressure fork VAS 5161/2  and pull knurled screw -4-  on the assembly cartridge VAS 5161/8A -2-  upwards by turning it clockwise and anti-clockwise in order to insert the valve keys.
   4. 7.4  Relieve pressure on the pressure fork VAS 5161/2  whilst pulling on the knurled screw -4-  .
   5. 7.5  Check that all valve keys are fitted correctly.

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   Assembly overview - valve keys

8. Disconnect compressed air from > VAS 6419 - cylinder head tensioning device  .
9. Repeat the procedure on all cylinders.
10. > VAS 5161A - Removal and installation device for valve cotters  must now be removed from the cylinder head.
11. Remove cylinder head from > VAS 6419 - cylinder head tensioning device  .
    1. 11.1  Disconnect compressed air from > VAS 6419 - cylinder head tensioning device  .
    2. 11.2  Disconnect supports from > VAS 6419 - cylinder head tensioning device  .
12. > VAS 6419 - Cylinder head tensioning device  must be removed from > VAS 6095A - engine and gearbox bracket  .